Manipulator system, manipulator system control method, and manipulator system control device

This is a continuation of International Application PCT/JP2021/030310 which is hereby incorporated by reference herein in its entirety.

The present invention relates to a manipulator system, a manipulator system control method, and a manipulator system control device.

A conventional electrically actuated medical device is provided with sensors for confirming that the medical device operates normally (for example, see PTL 1). To ensure normal operation of the medical device, the sensors are usually duplicated. For example, in an electrically actuated surgical instrument described in PTL 1, two sets formed of a motor position sensor and a processor are provided for one motor, and, when the value of at least one of the two motor position sensors is not normal, at least one processor stops the motor.

{PTL 1} Japanese Unexamined Patent Application, Publication No. 2020-185438

According to one aspect of the present invention, there is provided a manipulator system including: a manipulator; a driving device to which the manipulator is detachably connected and which electrically drives the manipulator; a control device configured to control the manipulator and the driving device; a first sensor provided in the driving device; and a second sensor provided in one of the manipulator and the driving device. The control device is configured to perform a first step of confirming that the driving device operates normally according to electric power on the basis of an output of the first sensor, and a second step of confirming that the manipulator is connected to the driving device on the basis of an output of the second sensor. The first step includes checking whether the first sensor is normal. The second step includes checking whether the second sensor is normal on the basis of the output of the first sensor that has been confirmed to be normal in the first step and the output of the second sensor.

According to another aspect of the present invention, there is provided a control method for controlling a manipulator system, the manipulator system including a manipulator and a driving device to which the manipulator is detachably connected and which electrically drives the manipulator, the control method including: performing a first step of confirming that the driving device operates normally according to electric power on the basis of an output of a first sensor; and performing a second step of confirming that the manipulator is connected to the driving device on the basis of an output of a second sensor. The first step includes checking whether the first sensor is normal. The second step includes checking whether the second sensor is normal on the basis of the output of the first sensor that has been confirmed to be normal in the first step and the output of the second sensor.

According to another aspect of the present invention, there is provided a control device for controlling a manipulator system, the manipulator system including a manipulator and a driving device to which the manipulator is detachably connected and which electrically drives the manipulator. The control device is configured to perform a first step of confirming that the driving device operates normally according to electric power on the basis of an output of a first sensor, and a second step of confirming that the manipulator is connected to the driving device on the basis of an output of a second sensor. The first step includes checking whether the first sensor is normal. The second step includes checking whether the second sensor is normal on the basis of the output of the first sensor that has been confirmed to be normal in the first step and the output of the second sensor.

A manipulator system control method, a manipulator system control device, and a manipulator system according to a first embodiment of the present invention will be described with reference to the drawings.

1 FIG. 100 1 2 1 1 3 1 4 1 2 5 6 As illustrated in, a manipulator systemaccording to this embodiment includes an electrically actuated manipulator, a driving deviceto which the manipulatoris detachably connected and which electrically drives the manipulator, an operation devicevia which an operator inputs an operation for driving the manipulator, a control devicefor controlling the manipulatorand the driving device, an image processor, and a display device.

1 1 1 7 1 8 1 6 5 6 The manipulatoris an electrically actuated flexible endoscope, a laparoscope (rigid endoscope), or a medical manipulator having an end effector or an arm at the distal end thereof to be inserted into a body cavity of a patient. Hereinbelow, the manipulatorwill be described by taking an electrically actuated flexible endoscope as an example. In the case where the manipulatoris an electrically actuated endoscope, a treatment instrumentis inserted into the manipulatorvia an extension tube. An endoscopic image acquired by the manipulatoris inputted to the display devicevia the image processorand is displayed on the display device.

3 2 2 3 3 3 2 4 2 2 1 a a The operation deviceis connected to an adapterof the driving devicevia an operation cable, and an operation input inputted to the operation deviceis inputted from the operation deviceto the driving device. The control deviceincorporated in the driving devicecontrols the driving deviceaccording to the operation input to operate the manipulatoraccording to the operation input.

1 2 FIGS.and 1 11 12 13 11 2 2 14 11 5 5 15 13 12 2 12 b a As illustrated in, the manipulatorincludes: an insertion parthaving a bending portion (movable portion); a first attachment/detachment partprovided at the proximal end of the insertion partand connected to adaptersof the driving device; a second attachment/detachment partprovided at the proximal end of the insertion partand connected to an adapterof the image processor; and a plurality of bending wires (driving wires)extending from the first attachment/detachment partto the bending portionand transmitting driving forces from the driving deviceto the bending portion.

11 12 11 15 11 11 The insertion partis a long, flexible member, and the bending portionis provided at the distal end of the insertion part. The plurality of bending wiresare disposed in an internal path (not illustrated) formed in the insertion partand extending in the longitudinal direction of the insertion part.

12 121 122 121 121 122 15 121 121 15 122 122 The bending portionincludes a first bending portion (movable portion)and a second bending portion (movable portion)provided on the proximal side of the first bending portion. The first bending portionand the second bending portionare each bendable upward, downward, leftward, and rightward. Four bending wireseach configured to bend the first bending portionupward, downward, leftward, or rightward are connected to the first bending portion. Four bending wireseach configured to bend the second bending portionupward, downward, leftward, or rightward are connected to the second bending portion.

2 FIG. 13 16 15 2 16 15 15 2 16 2 15 121 15 121 15 122 15 122 As illustrated in, the first attachment/detachment partincludes four wire attachment/detachment parts, which are mechanisms for attaching and detaching the bending wiresto and from the driving device. Each wire attachment/detachment partis provided at the proximal end of a pair of bending wires, and attaches and detaches the pair of bending wiresto and from the driving device. For example, the four wire attachment/detachment partsattach and detach, to and from the driving device, a pair of bending wiresfor bending the first bending portionvertically, a pair of bending wiresfor bending the first bending portionhorizontally, a pair of bending wiresfor bending the second bending portionvertically, and a pair of bending wiresfor bending the second bending portionhorizontally.

2 2 21 15 13 2 21 16 15 21 15 121 15 121 15 122 15 122 b The driving deviceis connected to a power source (not illustrated) and is operated by electric power supplied from the power source. The driving deviceincludes four wire driving parts, which are mechanisms for driving the bending wires. By connecting the first attachment/detachment partto the adapters, the four wire driving partsare coupled to the four wire attachment/detachment partsand can drive the pairs of bending wires. For example, the four wire driving partseach drive the corresponding one of the pair of bending wiresfor bending the first bending portionvertically, the pair of bending wiresfor bending the first bending portionhorizontally, the pair of bending wiresfor bending the second bending portionvertically, and the pair of bending wiresfor bending the second bending portionhorizontally.

3 3 FIGS.A andB 3 FIG.A 3 FIG.B 3 3 FIGS.A andB 3 3 FIGS.A andB 16 21 16 21 16 21 21 16 15 121 16 21 illustrate the configuration of the wire attachment/detachment partand the wire driving part.illustrates the wire attachment/detachment partand the wire driving partin a state of being separated from each other, andillustrates the wire attachment/detachment partand the wire driving partin a state of being connected to each other.illustrate, for example, the wire driving partand the wire attachment/detachment partincluding the pair of bending wiresfor bending the first bending portionvertically. The other wire attachment/detachment partsand the other wire driving partshave the same configuration as that in.

16 17 18 17 19 17 Each wire attachment/detachment partincludes a pair of rotary drums, a support membersupporting the pair of rotary drums, and a coupling mechanismcoupling the pair of rotary drumsto each other.

18 21 16 21 The support memberis a portion fixed to the wire driving partin a state in which the wire attachment/detachment partis coupled to the wire driving part.

17 18 11 17 17 17 17 a b a Each rotary drumis held by the support memberso as to be rotatable about a rotation axis B extending in a longitudinal direction A of the insertion part. Each rotary drumincludes a winding pulleydisposed coaxially with the rotation axis B and a gearfixed to the winding pulleyand disposed coaxially with the rotation axis B.

15 17 20 17 17 15 17 17 a a b a. The proximal end of each bending wireis guided to the winding pulleyvia a pulleyand is wound around the winding pulley. As a result of the rotary drumrotating about the rotation axis B, the bending wireis pulled in or fed out. The gearis a spur gear that rotates integrally with the winding pulley

16 21 19 17 15 19 19 19 19 a b c. In a state in which the wire attachment/detachment partis separated from the wire driving part, the coupling mechanismlimits rotation of the pair of rotary drumsto prevent the pair of bending wiresfrom loosening. The coupling mechanismincludes a columnar member, a link gear, and an elastic member

19 18 17 19 18 16 16 a a The columnar memberis supported by the support memberso as to be rotatable about a rotation axis C extending in the longitudinal direction A and movable forward and backward in the longitudinal direction. The rotation axis C is parallel to the rotation axes B of the rotary drums. The proximal end of the columnar memberpasses through the support member, protrudes to the outside of the wire attachment/detachment part, and is exposed on the proximal side of the wire attachment/detachment part.

19 19 b a The link gearis a spur gear fixed to the columnar memberand disposed coaxially with the rotation axis C.

19 19 19 2 c b a The elastic memberis, for example, a spring, and urges the link gearand the columnar membertoward a proximal side A.

3 FIG.A 16 21 19 19 19 19 17 17 17 15 12 15 17 12 b a c b b b As illustrated in, in a state in which the wire attachment/detachment partis separated from the wire driving part, the link gearand the columnar memberurged by the elastic memberare positioned at a first position. The link gearat the first position is located between the pair of gearsto mesh with both of the pair of gears. As a result, the pair of rotary drumsrotate in mutually opposite directions in conjunction with each other, and the pair of bending wiresare pulled in or fed out in conjunction with each other as if a single wire is looped (loop state). In the loop state, when the bending portionis bent upward or downward by an external force, the pair of bending wiresdo not loosen, and the relationship between the rotation angles of the rotary drumsand the bending angle of the bending portionis maintained.

3 FIG.B 16 21 19 1 26 19 19 19 19 17 17 15 a a c b a b b Meanwhile, as illustrated in, in a state in which the wire attachment/detachment partis connected to the wire driving part, the columnar memberis pressed toward a distal side Aby an engaging member(described below) against the urging force of the elastic member, and the link gearand the columnar memberare positioned at the second position. The link gearpositioned at the second position does not mesh with the pair of gears. As a result, the pair of rotary drumsdo not rotate in conjunction with each other, and the pair of bending wiresare pulled in or fed out independently of each other (antagonistic state).

16 22 18 16 21 23 17 15 25 21 Each wire attachment/detachment partincludes dogsprovided on the support memberto detect attachment/detachment between the wire attachment/detachment partand the wire driving part, and coupling partseach provided on the corresponding one of the pair of rotary drumsand serving as a mechanism for coupling the bending wireto a motor(described later) of the wire driving part.

22 18 16 16 16 21 22 21 26 3 FIG.B The dogsare members protruding from the support memberto the outside of the wire attachment/detachment partand exposed on the proximal side of the wire attachment/detachment part, and are, for example, pin-like members extending parallel to the rotation axes B and C. As illustrated in, in a state in which the wire attachment/detachment partis connected to the wire driving part, the dogsare inserted into the wire driving partthrough a support member.

23 17 16 23 23 a a The coupling partsare disc members fixed to the proximal ends of the winding pulleysand disposed coaxially with the rotation axes B, and are exposed on the proximal side of the wire attachment/detachment part. Each coupling parthas two fitting protrusionson the proximal-end surface thereof, on both sides of the rotation axis B.

21 24 25 24 26 24 The wire driving partincludes a pair of shafts, a pair of motors (power generation units)connected to the pair of shafts, and the support membersupporting the pair of shaftsin a rotatable manner.

24 26 24 17 13 2 Each shaftis supported by the support memberso as to be rotatable about a rotation axis D and movable forward and backward in the longitudinal direction A. The rotation axis D is the central axis of the shaftand is aligned with the rotation axis B of the rotary drumin a state in which the attachment/detachment partis connected to the driving device.

25 25 24 21 29 29 25 25 29 25 29 24 30 30 a b a b a b The motorsare, for example, direct-current motors. Each motorgenerates a rotational force, serving as a driving force, by electric power supplied from the power supply and rotates the corresponding shaftabout the rotation axis D. In the wire driving part, two encoders,and, for detecting the rotation speed and the rotation angle of the motorare provided for each motor. The first encoderis connected to the proximal end of the motor. The second encoderis connected to the shaftwith a pair of gears,and, meshing with each other.

26 26 17 19 26 21 19 16 21 26 19 a a a a a 3 4 FIGS.B and The support memberhas the engaging memberfor decoupling the pair of rotary drumsthat are coupled to each other by the coupling mechanism. The engaging memberis a columnar member exposed on the distal side of the wire driving partand is provided at a position corresponding to the columnar member. As illustrated in, in a state in which the wire attachment/detachment partis connected to the wire driving part, the engaging memberpresses the columnar memberto the second position.

21 27 24 25 17 Furthermore, the wire driving partincludes coupled partseach provided on the corresponding one of the pair of shaftsand serving as a mechanism for coupling the motorto the rotary drum.

27 24 24 27 21 27 27 a The coupled partsare disc members fixed to the distal ends of the shaftsand disposed coaxially with the rotation axes D, and rotate integrally with the shafts. The coupled partsare exposed on the distal side of the wire driving part. Each coupled parthas two fitting recessesin the distal-side surface thereof, on both sides of the rotation axis D.

3 4 FIGS.B and 23 27 23 27 25 15 17 17 23 27 24 25 15 17 a a As illustrated in, when the fitting protrusionsand the fitting recessesare fitted together, the coupling partsand the coupled partsare coupled together, and thus, the motorsare coupled to the bending wiresvia the rotary drums. In this state, the rotary drums, the coupling parts, the coupled parts, and the shaftsare integrally rotatable about the rotation axes C and D. Hence, the rotational forces (driving forces) generated by the motorsare transmitted, as forces in the longitudinal direction A, to the bending wiresvia the rotary drums.

100 31 32 33 34 35 36 The manipulator systemfurther includes tension sensors, torque sensors, attachment/detachment sensors, coupling sensors, current sensors, and antagonistic sensors.

31 36 16 32 33 34 35 21 31 32 33 34 35 36 4 31 32 33 34 35 36 4 The tension sensorand the antagonistic sensorare provided in each of the four wire attachment/detachment parts, and the torque sensors, the attachment/detachment sensors, the coupling sensors, and the current sensorsare provided in each of the four wire driving parts. These sensors,,,,, andare connected to the control device, and the outputs of the sensors,,,,, andare sequentially transmitted to the control device.

31 15 15 The tension sensoris provided for the each of the pair of bending wiresto detect the tensions of the bending wires.

32 25 25 32 24 25 The torque sensoris provided for each motorto detect the torque of the motor. For example, the torque sensoris attached to the shaftto detect the torque about the rotation axis D as the torque of the motor.

33 16 21 16 21 33 22 21 26 33 22 22 22 33 33 22 33 33 The attachment/detachment sensorsdetect attachment/detachment of the wire attachment/detachment partto/from the wire driving part. When the wire attachment/detachment partis connected to the wire driving part, the attachment/detachment sensorsare engaged with the dogsinserted into the wire driving partthrough the support member. The attachment/detachment sensorsinclude, for example, optical sensors that detect contact or proximity with the dogs, and detect engagement with the dogsby using the optical sensors. When the dogsare engaged with the attachment/detachment sensors, the outputs of the attachment/detachment sensorsare ON, whereas when the dogsare not engaged with the attachment/detachment sensors, the outputs of the attachment/detachment sensorsare OFF.

33 16 22 21 33 22 33 3 4 FIGS.A to The attachment/detachment sensorsare duplicated. Specifically, each wire attachment/detachment parthas two dogs, and each wire driving parthas two attachment/detachment sensors. In, only one set of the dogand the attachment/detachment sensoris illustrated.

34 25 34 25 15 23 27 24 23 27 34 23 27 34 The coupling sensoris provided for each motor. The coupling sensorsdetect that the motorsare coupled to the bending wiresby detecting that the coupling partsand the coupled partsare fitted together on the basis of the displacement of the shafts. When the coupling partsand the coupled partsare fitted together, the outputs of the coupling sensorsare ON, and when the coupling partsand the coupled partsare not fitted together, the outputs of the coupling sensorsare OFF.

3 FIG.B 27 23 2 24 34 24 24 23 27 24 a a. As illustrated in, the coupled partsare pressed by the coupling partsand moved to the proximal side Atogether with the shafts. The coupling sensorsinclude, for example, optical sensors that detect proximity of dogsprovided on the shafts, and detect fitting between the coupling partsand the coupled partson the basis of the proximity of the dogs

27 1 28 27 26 16 21 27 1 24 28 24 34 34 23 27 3 FIG.A a The coupled partsare urged toward the distal side Aby elastic members, such as compression springs, disposed between the coupled partsand the support member. As illustrated in, in a state in which the wire attachment/detachment partand the wire driving partare separated from each other, the coupled partshave been moved to the distal side Atogether with the shaftsby the urging force of the elastic members, and the dogsare located at positions away from the coupling sensors. In this state, the coupling sensorsdo not detect fitting between the coupling partsand the coupled parts.

4 FIG. 33 16 21 23 27 23 27 34 23 27 a a illustrates a state in which the attachment/detachment sensorshave detected connection between the wire attachment/detachment partand the wire driving part, but the coupling partsand the coupled partsare not fitted together due to misalignment between the fitting protrusionsand the fitting recesses. In this state, the coupling sensorsdo not detect fitting between the coupling partsand the coupled parts.

4 25 27 27 23 27 23 27 1 28 34 23 27 a a a a In this case, the control devicerotates the motorsto rotate the coupled parts. When the positions of the fitting recessescoincide with the positions of the fitting protrusions, the fitting recessesand the fitting protrusionsfit together, the coupled partsare moved to the distal side Aby the urging force of the elastic members, and the coupling sensorsdetect fitting between the coupling partsand the coupled parts.

35 25 25 The current sensoris provided for each motorto detect a current flowing through the motor.

36 16 15 36 The antagonistic sensoris provided for each wire attachment/detachment partto detect an antagonistic state of the pair of bending wires. Details of the antagonistic sensorwill be described in the fourth embodiment.

4 2 4 2 2 4 4 4 4 4 5 FIG. a b c d. The control deviceis a computer built into the driving deviceand capable of executing programs. The control devicemay be a computer disposed outside the driving deviceand connected to the driving device. As illustrated in, the control deviceincludes at least one processor, a memory, a storage unitcapable of storing programs and data, and an input/output controller

4 4 4 4 4 4 c c b a The storage unitis a non-volatile storage medium for storing programs and necessary data and is, for example, a ROM or a hard disk. The functions of the control device, which will be described below, are achieved by the programs stored in the storage unitbeing read into the memoryand executed by the processor. At least a part of the functions of the control devicemay be achieved by a dedicated logic circuit.

100 4 Next, a control method for controlling the manipulator systemperformed by the control devicewill be described.

1 2 4 100 1 2 3 4 6 FIG. The control method according to this embodiment is performed to check whether the manipulator, the driving device, and the control devicewill operate normally at the time of starting the manipulator system. As illustrated in, the control method includes a driving-device starting sequence (first step) S, a manipulator connecting sequence (second step) S, a bending-portion initialization sequence (third step) S, and a bending-portion calibration sequence S.

4 4 3 2 After the bending-portion calibration sequence S, the control devicereceives an operation input from the operation device, and controls the driving deviceaccording to the operation input.

7 FIG. 1 2 3 4 31 32 33 34 illustrates steps performed in each of the sequences S, S, S, and S, and the sensors,,, andused in each step.

1 2 2 29 29 32 1 11 2 4 12 2 a b The driving-device starting sequence Sis a sequence for starting the driving deviceand confirming that the driving deviceoperates normally on the basis of the outputs of the encodersandand the torque sensors (first sensor). The driving-device starting sequence Sincludes step Sof starting the driving deviceincluding the control device, and step Sof performing self-diagnosis of the driving device.

12 11 4 4 25 29 29 a a b In step Ssubsequent to step S, the control deviceperforms inspections for checking whether the processor, the motor, and the encodersand, which are supplied with power, operate normally.

25 4 25 25 29 29 25 29 29 29 29 25 29 29 29 29 29 29 4 25 29 29 29 29 a b a b a b a b a b a b a b a b. In the inspection of the motor, the control devicedrives the motorand checks the rotation angle of the motor, which is the output of the two encodersand. When the motorand the two encodersandare all normal, the outputs of the two encodersandare identical to each other. When the motoris faulty, there is no output from either of the two encodersand. When one of the encodersandis faulty, there is no output from only the faulty encoder, or the outputs of the two encodersanddo not match. The control devicechecks whether the motorand the two encodersandare normal on the basis of the outputs of the two encodersand

12 4 32 32 29 29 a b. In step S, the control deviceperforms an inspection for checking whether the torque sensoris normal on the basis of the output of the torque sensorand the outputs of the encodersand

32 32 25 4 25 29 29 25 32 32 32 32 29 29 25 4 32 a b a b When the torque sensoris normal, the torque, which is the output of the torque sensor, increases with the rotation of the motor. The control devicerotates the motor, confirms that the encodersandhave detected the rotation of the motor, and then checks the output of the torque sensor. When the output of the torque sensoris higher than or equal to a predetermined value, it is determined that the torque sensoris normal. On the other hand, when the output of the torque sensoris less than the predetermined value despite that the encodersandhave detected the rotation of the motor, the control devicedetermines that the torque sensoris abnormal.

25 25 12 4 32 32 35 The rotational torque of the motorcan also be detected from the current flowing through the motor. Thus, in step S, the control devicemay check whether the torque sensoris normal on the basis of the output of the torque sensorand the output of the current sensor.

4 25 29 29 32 4 2 4 25 29 29 32 4 a a b a a b When it is confirmed that the processor, the motor, the encodersand, and the torque sensorare all normal, the control devicesubsequently performs the manipulator connecting sequence S. When any abnormality is detected in at least one of the processor, the motor, the encodersand, and the torque sensor, the control devicetransitions to an error state and terminates the control method.

2 1 2 33 34 2 21 16 1 21 2 22 25 15 23 34 24 25 15 The manipulator connecting sequence Sis a sequence for confirming that the manipulatoris connected to the driving deviceon the basis of the outputs of the attachment/detachment sensorsand the coupling sensors (second sensor). The manipulator connecting sequence Sincludes step Sof confirming that the wire attachment/detachment partof the manipulatoris connected to the wire driving partof the driving device, step Sof confirming that the motorsare coupled to the bending wires, step Sof inspecting the coupling sensors, and step Sof confirming that the driving force is transmitted from the motorsto the bending wires.

21 4 16 21 33 33 4 16 21 22 33 4 13 21 In step S, the control deviceconfirms connection between the wire attachment/detachment partand the wire driving parton the basis of the output of the duplicated attachment/detachment sensors. Specifically, if the outputs of both the two attachment/detachment sensorsare ON, the control devicedetermines that the wire attachment/detachment partand the wire driving partare connected to each other and proceeds to the next step S. When the output of at least one of the two attachment/detachment sensorsis OFF, the control devicedetermines that the attachment/detachment partand the wire driving partare not connected to each other.

22 4 25 15 23 27 34 32 In step S, the control deviceconfirms that the motorsare coupled to the bending wiresvia the coupling partsand the coupled parts, which are coupled to each other, on the basis of the outputs of the coupling sensorsand the torque sensors.

8 FIG.A 4 25 221 25 27 27 23 27 23 34 222 a a Specifically, as illustrated in, the control devicerotates the motors(step S). The rotation of the motorsrotates the coupled parts, and, when the fitting recessesare aligned with the fitting protrusions, the coupled partsare coupled to the coupling parts, and the outputs of the coupling sensorsbecome ON (YES in step S).

34 222 4 32 223 25 15 23 27 25 25 32 223 4 25 15 25 224 32 223 4 25 15 25 225 226 After confirming that the outputs of the coupling sensorsare ON (YES in step S), the control devicesubsequently checks the outputs of the torque sensors(step S). In a state in which the motorsare coupled to the bending wiresvia the coupling partsand the coupled parts, which are coupled to each other, the torques of the motorsincrease due to an increase in the load on the motors. If the outputs of the torque sensorsare higher than or equal to a predetermined value (YES in step S), the control devicedetermines that the motorsare properly coupled to the bending wires, and stops the motors(step S). If the outputs of the torque sensorsare less than the predetermined value (NO in step S), the control devicedetermines that the motorsare not properly coupled to the bending wires, stops the motors(step S), and transitions to an error state (step S).

223 4 32 25 32 25 15 25 15 In step S, the control devicemay check the difference between the outputs of the torque sensorsbefore and after the rotation of the motors, instead of the detected torques, which are the outputs of the torque sensors. In this case, if the difference is greater than or equal to the predetermined value, it is determined that the motorsare properly coupled to the bending wires, and if the difference is less than the predetermined value, it is determined that the motorsare not properly coupled to the bending wires.

4 23 22 23 4 34 34 1 The control deviceperforms step Sin parallel with step S. In step S, the control devicechecks whether the coupling sensorsare normal on the basis of the outputs of the coupling sensorsand the outputs of the torque sensors that have been confirmed to be normal in sequence S.

8 FIG.B 4 25 231 32 232 34 233 34 233 4 34 234 34 4 34 235 Specifically, as illustrated in, the control devicerotates the motors(step S), and, after the outputs of the torque sensorshave increased to a predetermined value or more (YES in step S), checks the outputs of the coupling sensors(step S). If the outputs of the coupling sensorsare ON (YES in step S), the control devicedetermines that the coupling sensorsare normal (step S). When the coupling sensorsare OFF, the control devicedetermines that the coupling sensorsare abnormal (step S).

24 4 2 32 25 27 24 4 25 32 32 25 32 25 4 32 25 4 Next, in step S, the control deviceinspects a power transmission mechanism in the driving deviceon the basis of the outputs of the torque sensors. The power transmission mechanism is a mechanism for transmitting a driving force from the motorsto the coupled parts, and includes members, such as the rotation shafts, on a driving-force transmission path. The control devicerotates the motorsand checks the outputs of the torque sensors. If the power transmission mechanism is normal, the outputs of the torque sensorschange in response to the rotation of the motors. If the outputs of the torque sensorschange in response to the rotation of the motors, the control devicedetermines that the power transmission mechanism is normal. If the outputs of the torque sensorsdo not change in response to the rotation of the motors, the control devicedetermines that the power transmission mechanism is abnormal.

21 22 23 24 4 3 21 22 23 24 4 If no abnormality is confirmed in steps S, S, S, and S, the control devicesubsequently performs the bending-portion initialization sequence S. If any abnormality is confirmed in any of steps S, S, S, and S, the control devicetransitions to an error state and terminates the control method.

3 12 1 25 31 12 3 31 12 32 15 32 31 34 1 The bending-portion initialization sequence Sis a sequence for confirming that the bending portionof the manipulatoroperates normally according to the driving force of the motorson the basis of the outputs of the tension sensors (third sensor), and bringing the bending portionto an initial state before calibration. The bending-portion initialization sequence Sincludes step Sof initializing the bending angle of the bending portion, step Sof applying initial tensions to the bending wires, step Sof inspecting the tension sensors, and step Sof inspecting a power transmission mechanism in the manipulator.

31 4 12 31 4 25 121 15 121 31 4 25 122 15 122 31 In step S, the control devicestraightens the bending portionon the basis of the outputs of the tension sensors. For example, the control devicerotates the four motorsfor the first bending portionto make the tensions of the four bending wiresfor the first bending portionequal to one another, while monitoring the outputs of the tension sensors. The control devicealso rotates the four motorsfor the second bending portionto make the tensions of the four bending wiresfor the second bending portionequal to one another while monitoring the outputs of the tension sensors.

32 4 15 31 4 25 31 25 31 15 Next, in step S, the control deviceapplies a predetermined initial tension to each of the eight bending wireson the basis of the outputs of the tension sensors. For example, the control devicerotates the motorswhile monitoring the outputs of the tension sensorsand stops the motorsat rotation angles at which the tensions detected by the tension sensorsare predetermined initial tensions to apply initial tensions to the bending wires.

33 4 31 31 32 1 Next, in step S, the control devicechecks whether the tension sensorsare normal on the basis of the outputs of the tension sensorsand the outputs of the torque sensorsthat have been confirmed to be normal in the sequence S.

9 FIG. 9 FIG. 31 32 31 32 31 31 32 illustrates the relationship between the outputs of the tension sensorsand the outputs of the torque sensors. As illustrated in, when the tension sensorsare normal, there is a predetermined correlation between the torques, which are the outputs of the torque sensors, and the tensions, which are the outputs of the tension sensors, and the tensions increase as the torques increases. Hence, the outputs of the tension sensorscan be estimated from the outputs of the torque sensors.

8 FIG.C 4 25 331 15 25 32 332 4 31 333 4 31 34 25 4 331 333 31 As illustrated in, the control devicerotates the motors(step S), and then calculates estimated tensions of the bending wiresfrom the torques of the motors, which are the outputs of the torque sensors(step S). Next, the control devicecalculates the difference between the detected tensions, which are the outputs of the tension sensors, and the estimated tensions. If the magnitude of the difference is less than or equal to a predetermined value (YES in step S), the control devicedetermines that the tension sensorsare normal and proceeds to the next step S. While the motorsare rotated, the control devicerepeats steps Sto Sto constantly perform inspection of the tension sensors.

333 4 31 25 334 335 If the difference is larger than the predetermined value (NO in step S), the control devicedetermines that the tension sensorsare abnormal, stops the motors(step S), and transitions to an error state (step S).

331 332 4 25 15 31 32 In steps Sand S, the control devicemay calculate estimated torques of the motorsfrom the detected tensions of the bending wires, which are the outputs of the tension sensors, and calculate the difference between the detected torques, which are the outputs of the torque sensors, and the estimated torques.

34 4 1 31 23 12 23 17 15 4 25 31 31 25 31 25 4 31 25 4 In step S, the control deviceinspects the power transmission mechanism in the manipulatoron the basis of the outputs of the tension sensors. The power transmission mechanism is a mechanism for transmitting a driving force from the coupling partsto the bending portion, and includes members, such as the coupling parts, the rotary drums, and the bending wires, on the driving-force transmission path. The control devicerotates the motorsand checks the outputs of the tension sensors. If the power transmission mechanism is normal, the outputs of the tension sensorschange in response to the rotation of the motors. If the outputs of the tension sensorschange in response to the rotation of the motors, the control devicedetermines that the power transmission mechanism is normal. If the outputs of the tension sensorsdo not change in response to the rotation of the motors, the control devicedetermines that the power transmission mechanism is abnormal.

31 32 33 34 4 4 31 32 33 34 4 If no abnormality is confirmed in steps S, S, S, and S, the control devicesubsequently performs the bending-portion calibration sequence S. If any abnormality is confirmed in any of steps S, S, S, and S, the control devicetransitions to an error state and terminates the control method.

4 25 12 12 25 25 12 25 12 4 4 25 25 12 25 29 29 12 a b The bending-portion calibration sequence Sis a sequence for calibrating the relationship between the amounts of rotation of the motorsand the bending angle of the bending portion. In order to accurately control the bending angle of the bending portionby means of rotation of the motors, the amounts of rotation of the motorsand the bending angle of the bending portionneed to have a predetermined relationship. However, the relationship between the amounts of rotation of the motorsand the bending angle of the bending portionmay change for some reason. In the sequence S, the control devicerotates the motorsto adjust the relationship between the amounts of rotation of the motorsand the bending angle of the bending portionon the basis of the rotation angles of the motorsdetected by the encodersandand the bending angle of the bending portionacquired from an endoscopic image.

4 100 3 After completion of the sequence S, the manipulator systemis ready to be operated by the operation device.

1 2 11 13 14 1 11 13 14 2 2 When connecting the manipulatorto the driving device, an operator, such as a nurse, moves while holding the insertion partand the attachment/detachment partsandwith hands and performs a connecting task. Hence, to enable the operator to easily prepare the manipulatorhimself or herself, it is important to reduce the weight and size of the insertion partand the attachment/detachment partsand. The driving deviceis also desired to be small so that the user can install the driving deviceanywhere.

100 1 1 121 122 31 32 34 15 31 32 34 100 The manipulator systemhaving the electrically actuated and detachable manipulatorhas a number of sensors. For example, the manipulatorhaving the two-stage bending portionsandhas the tension sensors, the torque sensors, and the coupling sensorscorresponding to the eight bending wires. Because these sensors,, andare expensive, reducing the number of sensors is important to reduce the product cost of the manipulator system.

34 23 34 34 32 32 34 32 34 34 32 34 34 34 2 According to this embodiment, in the inspection of the coupling sensorsin step S, it is checked whether the coupling sensorsare normal on the basis of the outputs of the coupling sensorsand the outputs of the torque sensors. If both the torque sensorsand the coupling sensorsare normal, the outputs of the torque sensorsand the outputs of the coupling sensorscorrelate with each other. Thus, by combining the coupling sensorswith the torque sensorsthat have been confirmed to be normal, it is possible to detect an abnormality of the coupling sensorswithout duplicating the coupling sensors. Thus, it is possible to reduce the number of coupling sensorsprovided in the driving device.

22 15 25 34 32 Furthermore, in the confirmation of coupling in step S, coupling between the bending wiresand the motorscan be doubly confirmed on the basis of the outputs of the coupling sensorsand the torque sensors.

31 33 31 31 32 32 31 32 31 31 32 31 31 31 1 13 Furthermore, according to this embodiment, in the inspection of the tension sensorsin step S, it is checked whether the tension sensorsare normal on the basis of the outputs of the tension sensorsand the outputs of the torque sensors. If both the torque sensorsand the tension sensorsare normal, the outputs of the torque sensorsand the outputs of the tension sensorscorrelate with each other. Thus, by combining the tension sensorswith the torque sensorsthat have been confirmed to be normal, it is possible to detect an abnormality of the tension sensorswithout duplicating the tension sensors. Thus, it is possible to reduce the number of the tension sensorsprovided in the manipulator. Thus, it is possible to reduce the size and weight of the attachment/detachment part.

Next, a manipulator system control method, a manipulator system control device, and a manipulator system according to a second embodiment of the present invention will be described with reference to the drawings.

In this embodiment, configurations different from those in the first embodiment will be described, and configurations common to those in the first embodiment will be denoted by the same reference signs, and the descriptions thereof will be omitted.

100 1 2 4 3 5 6 As in the first embodiment, the manipulator systemaccording to this embodiment includes the manipulator, the driving device, the control device, the operation device, the image processor, and the display device.

10 FIG. 10 FIG. 1 2 3 4 31 32 33 34 2 illustrates steps performed in each of the sequences S, S, S, and Sof the control method according to this embodiment, and the sensors,,, andused in each step. As illustrated in, the control method according to this embodiment differs from that according to the first embodiment in the manipulator connecting sequence S.

2 21 25 31 22 25 15 24 The manipulator connecting sequence Sin this embodiment includes step S, step Sof inspecting the tension sensors, step S′ of confirming that the motorsare coupled to the bending wires, and step S.

25 4 31 31 32 1 33 4 25 15 25 4 31 22 4 31 25 In step S, the control devicechecks whether the tension sensorsare normal on the basis of the outputs of the tension sensorsand the outputs of the torque sensorsthat have been confirmed to be normal in the sequence S. Specifically, similarly to step Sin the first embodiment, the control devicerotates the motors, calculates estimated tensions of the bending wiresfrom the torques of the motors, and calculates the difference between the detected tensions and the estimated tensions. If the difference is less than or equal to a predetermined value, the control devicedetermines that the tension sensorsare normal and proceeds to the next step S′. If the magnitude of the difference is larger than the predetermined value, the control devicedetermines that the tension sensorsare abnormal, stops the motors, and transitions to an error state.

25 4 25 15 31 32 In step S, the control devicemay calculate estimated torques of the motorsfrom the detected tensions of the bending wires, which are the outputs of the tension sensors, and calculate the difference between the detected torques, which are the outputs of the torque sensors, and the estimated torque.

22 4 25 15 23 27 31 32 In step S′, the control deviceconfirms that the motorsare coupled to the bending wiresvia the coupling partsand the coupled parts, which are coupled to each other, on the basis of the outputs of the tension sensorsand the torque sensors.

11 FIG. 4 25 221 25 27 27 23 27 23 15 a a Specifically, as illustrated in, the control devicerotates the motors(step S). The rotation of the motorsrotates the coupled parts, and, when the fitting recessesare aligned with the fitting protrusions, the coupled partsare coupled to the coupling parts, increasing the tensions of the bending wires.

15 227 4 32 25 15 25 15 32 223 4 25 15 25 224 32 223 4 25 15 25 225 226 After confirming that the tensions of the bending wireshave increased to a predetermined value or more (YES in step S), the control devicesubsequently checks the outputs of the torque sensors. In a state in which the motorsare coupled to the bending wires, the torques of the motorsincrease due to the tensions of the bending wires. If the outputs of the torque sensorsare higher than or equal to a predetermined value (YES in step S), the control devicedetermines that the motorsare properly coupled to the bending wires, and stops the motors(step S). If the outputs of the torque sensorsare less than the predetermined value (NO in step S), the control devicedetermines that the motorsare not properly coupled to the bending wires, stops the motors(step S), and transitions to an error state (step S).

31 25 31 31 32 31 32 31 31 31 1 As described above, according to this embodiment, in the inspection of the tension sensorsin step S, it is checked whether the tension sensorsare normal on the basis of the outputs of the tension sensorsand the outputs of the torque sensors. As described above, by combining the tension sensorswith the torque sensorsthat have been confirmed to be normal, it is possible to detect an abnormality of the tension sensorswithout duplicating the tension sensors. Thus, it is possible to reduce the number of the tension sensorsprovided in the manipulator.

22 15 25 31 32 34 2 Furthermore, according to this embodiment, in step S′, coupling between the bending wiresand the motorsis doubly confirmed on the basis of the outputs of the tension sensorsand the torque sensors. This makes it possible to omit the coupling sensorsand thus to further reduce the number of sensors provided in the driving devicecompared with that in the first embodiment.

Next, a manipulator system control method, a manipulator system control device, and a manipulator system according to a third embodiment of the present invention will be described with reference to the drawings.

In this embodiment, configurations different from those in the first embodiment will be described, and configurations common to those in the first embodiment will be denoted by the same reference signs, and the description thereof will be omitted.

100 1 2 4 3 5 6 As in the first embodiment, the manipulator systemaccording to this embodiment includes the manipulator, the driving device, the control device, the operation device, the image processor, and the display device.

12 FIG. 12 FIG. 1 2 3 4 31 32 33 34 35 2 3 illustrates steps performed in each of the sequences S, S, S, and Sof the control method according to this embodiment, and the sensors,,,, andused in each step. As illustrated in, the control method according to this embodiment differs from that according to the first embodiment in the manipulator connecting sequence Sand the bending-portion initialization sequence S.

2 21 26 32 22 25 15 24 The manipulator connecting sequence Sin this embodiment includes step S, step Sof inspecting the torque sensors, step S″ of confirming that the motorsare coupled to the bending wires, and step S.

26 4 32 32 35 In step S, the control devicechecks whether the torque sensorsare normal on the basis of the outputs of the torque sensorsand the output of the current sensors (fourth sensor).

13 FIG. 13 FIG. 32 35 32 32 25 35 32 35 illustrates the relationship between the outputs of the torque sensorsand the outputs of the current sensors. As illustrated in, when the torque sensorsare normal, there is a predetermined correlation between the magnitudes of the torques, which are the outputs of the torque sensors, and the magnitudes of the currents of the motors, which are the outputs of the current sensors, and the torques increase as the currents increase. Hence, the outputs of the torque sensorscan be estimated from the outputs of the current sensors.

4 25 25 25 35 4 32 4 32 4 32 For example, the control devicerotates the motors, and calculates estimated torques of the motorsfrom the currents of the motorsdetected by the current sensors. Next, the control devicecalculates the difference between the detected torques, which are the outputs of the torque sensors, and the estimated torques. If the magnitude of the difference is less than or equal to a predetermined value, the control devicedetermines that the torque sensorsare normal, and if the magnitude of the difference is larger than the predetermined value, the control devicedetermines that the torque sensorsare abnormal.

22 4 25 15 23 27 32 35 Next, in step S″, the control deviceconfirms that the motorsare coupled to the bending wiresvia the coupling partsand the coupled parts, which are coupled to each other, on the basis of the outputs of the torque sensorsand the outputs of the current sensors.

14 FIG. 4 25 221 25 27 27 23 27 23 25 a a Specifically, as illustrated in, the control devicerotates the motors(step S). The rotation of the motorsrotates the coupled parts, and, when the fitting recessesare aligned with the fitting protrusions, the coupled partsare coupled to the coupling parts, increasing the torques of the motors.

25 228 4 35 25 15 25 25 35 229 4 25 15 25 224 35 229 4 25 15 25 225 226 After confirming that the torques of the motorshave increased to a predetermined value or more (YES in step S), the control devicesubsequently checks the outputs of the current sensors. In a state in which the motorsare coupled to the bending wires, the currents of the motorsincrease due to an increase in the load on the motors. If the outputs of the current sensorsare higher than or equal to a predetermined value (YES in step S), the control devicedetermines that the motorsare properly coupled to the bending wiresand stops the motors(step S). If the outputs of the current sensorsare less than the predetermined value (NO in step S), the control devicedetermines that the motorsare not properly coupled to the bending wires, stops the motors(step S), and transitions to an error state (step S).

3 31 32 35 32 34 1 The bending-portion initialization sequence Sin this embodiment includes step S, step S, step Sof inspecting the torque sensors, and step Sof inspecting the power transmission mechanism in the manipulator.

35 26 4 32 32 35 In step S, similarly to step S, the control devicechecks whether the torque sensorsare normal on the basis of the outputs of the torque sensorsand the outputs of the current sensors.

32 26 32 32 35 32 35 32 35 32 32 As described above, according to this embodiment, in the inspection of the torque sensorsin step S, it is checked whether the torque sensorsare normal on the basis of the outputs of the torque sensorsand the outputs of the current sensors. The outputs of the torque sensorsand the outputs of the current sensorscorrelate with each other. Hence, by combining the torque sensorsand the current sensors, it is possible to detect an abnormality of the torque sensorswithout duplicating the torque sensors.

22 15 25 32 35 34 2 Furthermore, in step S″, coupling between the bending wiresand the motorsis doubly confirmed on the basis of the outputs of the torque sensorsand the outputs of the current sensors. This makes it possible to omit the coupling sensorsand thus to further reduce the number of sensors provided in the driving devicecompared with that in the first embodiment.

Next, a manipulator system control method, a manipulator system control device, and a manipulator system according to a fourth embodiment of the present invention will be described with reference to the drawings.

In this embodiment, configurations different from those in the first embodiment will be described, and configurations common to those in the first embodiment will be denoted by the same reference signs, and the description thereof will be omitted.

100 1 2 4 3 5 6 As in the first embodiment, the manipulator systemaccording to this embodiment includes the manipulator, the driving device, the control device, the operation device, the image processor, and the display device.

15 FIG. 15 FIG. 1 2 3 4 31 32 33 34 36 2 illustrates steps performed in each of sequences S, S, S, and Sof the control method according to this embodiment, and the sensors,,,, andused in each step. As illustrated in, the control method according to this embodiment differs from that according to the first embodiment in the manipulator connecting sequence S.

2 21 16 1 21 2 22 23 24 The manipulator connecting sequence Sin this embodiment includes step S′ of confirming that the wire attachment/detachment partof the manipulatoris connected to the wire driving partof the driving device, step S, step, and step S.

21 4 16 21 33 36 In step S′, the control deviceconfirms connection between the wire attachment/detachment partand the wire driving parton the basis of the outputs of the attachment/detachment sensors (fifth sensor)and the outputs of the antagonistic sensors (sixth sensor).

36 15 15 19 19 19 36 19 19 a b a a Each antagonistic sensordetects an antagonistic state of a pair of bending wires. When the pair of bending wiresare in an antagonistic state, the columnar memberand the gearof the coupling mechanismare positioned at the second position. For example, the antagonistic sensorincludes an optical sensor that detects contact or proximity with the columnar member, and detects the antagonistic state by detecting that the columnar memberis positioned at the second position with the optical sensor.

16 FIG. 21 4 33 211 36 212 36 16 4 16 21 36 4 16 21 213 As illustrated in, in step S′, the control deviceconfirms that the attachment/detachment sensorsare ON (YES in step S), and then checks the outputs of the antagonistic sensors(step S). If the outputs of all the antagonistic sensorsof the four wire attachment/detachment partsare ON, the control devicedetermines that the wire attachment/detachment partsand the wire driving partsare connected to each other. If the output of at least one of the antagonistic sensorsis OFF, the control devicedetermines that the wire attachment/detachment partsand the wire driving partsare not connected to each other, and transitions to an error state (step S).

21 16 21 33 36 16 21 33 33 2 As described above, according to this embodiment, in step S′, connection between the wire attachment/detachment partsand the wire driving partsis doubly confirmed on the basis of the outputs of the attachment/detachment sensorsand the outputs of the antagonistic sensors. This makes it possible to reliably and accurately detect whether the wire attachment/detachment partsand the wire driving partsare connected to each other without duplicating the attachment/detachment sensors, and thus to reduce the number of attachment/detachment sensorsprovided in the driving devicecompared with that in the first embodiment.

21 21 21 Step S′ in this embodiment may be applied to the second and third embodiments. Specifically, step S′ may be performed instead of step Sin the second and third embodiments.

1 2 3 In the above-described embodiments, the sensor in which an abnormality has been detected in sequence S, S, or Smay be notified to an operator. This configuration enables the operator, upon being notified of the sensor in which an abnormality has been detected, to appropriately determine which of the manipulator and the driving device is to be replaced.

32 12 32 34 23 34 31 33 31 For example, in the first embodiment, if an abnormality of the torque sensorsis detected in the inspection in step S, the abnormality of the torque sensorsis notified. If an abnormality of the coupling sensorsis detected in the inspection in step S, the abnormality of the coupling sensorsis notified. If an abnormality of the tension sensorsis detected in the inspection in step S, the abnormality of the tension sensorsis notified.

32 34 31 The operator replaces the driving device with another driving device if an abnormality of the torque sensorsor the coupling sensorsis detected, and replaces the manipulator with another manipulator if an abnormality of the tension sensorsis detected.

1 1 12 Although the manipulatorhas been described as an electrically actuated flexible endoscope in the above-described embodiments, the manipulatoris not limited thereto and may be another device that has an electrically driven movable portion. For example, the manipulator may be a rigid endoscope including the bending portion, or may be a surgical treatment instrument including a movable portion that performs a desired operation, such as opening/closing or advancing/retracting, according to the driving force transmitted from the motors through the driving wires.

1 2 3 4 3 In the above-described embodiments, the inspections performed in steps S, S, S, and Smay be performed not only at the time of starting, but also at any timing after operation by the operation devicebecomes possible.

25 15 Although it has been described that the power generation units include the motorsin the above-described embodiments, the power generation units may be in other forms as long as the power generation units can generate a driving force for moving the movable portion. For example, the power generation units may include actuators that generate a linear force as the driving force. The design of the power transmission mechanism between the power generation units and the bending wiresmay be changed according to the form of the power generation unit.

1 Manipulator, endoscope 2 Driving device 4 Control device 12 121 122 ,,Bending portion (movable portion) 16 Wire attachment/detachment part 21 Wire driving part 25 Motor (power generation unit) 31 Tension sensor (second sensor, third sensor) 32 Torque sensor (first sensor) 33 Attachment/detachment sensor (fifth sensor) 34 Coupling sensor (second sensor) 35 Current sensor (fourth sensor) 36 Antagonistic sensor (sixth sensor) 1 SDriving-device starting sequence (first step) 2 SManipulator connecting sequence (second step) 3 SBending-portion initialization sequence (third step)